Corrosion & Fouling
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Program Professional Framework
Corrosion & Fouling
Program Overview
Corrosion and fouling together drive a large share of unplanned maintenance, energy loss and integrity incidents in oil, gas and refining facilities. This course covers the main corrosion mechanisms, including CO2 and H2S corrosion, oxygen corrosion, microbiologically influenced corrosion, under-deposit attack and environmental cracking, together with fouling mechanisms in heat exchangers, crude preheat trains and cooling water systems. Participants learn mitigation through material selection to NACE MR0175/ISO 15156, inhibitors, cathodic protection and coatings, and fouling control through design, monitoring and cleaning, supported by monitoring programmes suited to hot, humid and high-salinity Gulf conditions.
Learning Outcomes
- ✓Identify the dominant corrosion mechanisms for a given process fluid, temperature and material.
- ✓Select materials for sour service using NACE MR0175/ISO 15156 principles.
- ✓Design a corrosion inhibition and monitoring programme using coupons, probes and inspection data.
- ✓Explain the role of cathodic protection and coatings in protecting pipelines and tanks.
- ✓Analyse heat exchanger performance data to quantify fouling and its cost in energy and throughput.
- ✓Recommend fouling mitigation measures, including design changes, antifoulants and cleaning strategies.
Target Audience
- Corrosion and materials engineers
- Process and production engineers
- Inspection and integrity engineers
- Maintenance and reliability engineers
Detailed Program Modules
01Corrosion Fundamentals
- Electrochemistry of corrosion
- Forms of corrosion and their appearance
- Cost and integrity impact
02Corrosion in Oil and Gas Systems
- CO2 and H2S corrosion
- Oxygen corrosion and MIC in water systems
- Under-deposit corrosion and erosion-corrosion
03Environmental Cracking and Material Selection
- Sulphide stress cracking and HIC
- Chloride stress corrosion cracking
- Sour service material selection with NACE MR0175/ISO 15156
04Corrosion Mitigation and Monitoring
- Inhibitor selection and treatment programmes
- Cathodic protection and coatings
- Coupons, ER probes and inspection data
05Fouling Mechanisms and Impact
- Crystallisation, particulate, biological and chemical fouling
- Fouling in crude preheat trains and cooling water
- Fouling resistance and heat transfer loss
06Fouling Mitigation and Management
- Design and operational measures
- Antifoulants and water treatment
- Cleaning methods and performance monitoring
Training Methodology
Applied Project & Assessment
Applied Project
Participants assess a provided process unit or flowline case, identify corrosion and fouling threats, propose material, inhibition and monitoring measures, quantify the energy cost of exchanger fouling and present an integrated mitigation plan.
Assessment
Short diagnostic at the start, practical tasks linked to each learning outcome, and evaluation of the applied project against published criteria.
University Certificate & International Accreditation
Professional Certificate accredited by Universiti Teknologi Malaysia (UTM) in Corrosion & Fouling
International accreditation: European Health and Safety Agency (EHSA)